Greenlee H4802 Series User manual

INSTRUCTION MANUAL
H4802 Series
Pole Tampers
99930196 REV 4 © 2016 Greenlee Textron Inc. 12/16
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
Español............... 13
Français.............. 25

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose of this Manual
This instruction manual is intended to familiarize person-
nel with the safe operation and maintenance procedures
for the following Greenlee Utility tools:
H4802 (42198)
H4802-1 (42199)
H4802-3 (42200)
H4802-5 (42201)
H4802-6 (42202)
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge at www.greenlee.com.
Other Publications
Tool Owners/Users
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
Greenlee Utility Authorized Service Centers
Service Manual:
H4802: Publication 99910420
H4802-1: Publication 99910420
H4802-3: Publication 99910446
H4802-5: Publication 99910446
H4802-6: Publication 99910420
All specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
KEEP THIS MANUAL
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Other Publications......................................................... 2
Important Safety Information .....................................3–4
Identication.................................................................. 5
Specications................................................................ 6
Setting the Super Spool™............................................. 7
Hoses and Fittings ........................................................ 7
Hose Connections......................................................8–9
Typical Setup..............................................................8–9
Setup........................................................................... 10
Operation................................................................10–11
Maintenance................................................................ 11
Troubleshooting........................................................... 12
Español...................................................................13–24
Français..................................................................25–36
Illustrations and Parts Lists ....................................37–40
Description
Greenlee Utility Pole Tampers operate with either open-
center or closed-center hydraulic systems and are
intended for setting utility poles, compacting asphalt,
and general construction backll tamping. Quiet, light-
weight, and low-maintenance, Greenlee Utility tampers
are available in 1520 mm (60"), 1830 mm (72") and 2160
mm (85") lengths.
Models H4802 and H4802-1 include a remote control
valve.

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning
could result in severe injury or death.
Electric shock hazard:
This tool is not insulated. When
using this unit near energized elec-
trical lines:
• Use only certied non-conductive
hoses and proper personal protec-
tive equipment.
• Select and maintain the hydraulic
uid to meet the minimum dielec-
tric standards required by your
safety department.
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punctures
skin causing serious injury, gangrene
or death. If you are injured by
escaping oil, seek medical attention
immediately.
Do not disconnect tool, hoses, or ttings while
the tool is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 23 l/min (6 gpm)
• Pressure relief: 138 bar (2000 psi)
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
• Do not change accessories, inspect, or clean
tool when it is connected to a power source.
Accidental start-up can result in serious injury.
• Maintain a rm grip on tool, using both hands at
all times. Serious injury can result if an operator
does not control the tool.
Failure to observe these warnings could result in
severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Wear foot protection when using
this tool.
Failure to observe this warning
could result in serious injury.
Wear hearing protection when using
this tool.
Long-term exposure to high noise
levels could result in hearing
damage.
Do not reverse hydraulic ow. Operation with
hydraulic ow reversed can cause tool malfunction.
Connect the supply (pressure) hose and return (tank)
hose to the proper tool ports.
Failure to observe this warning could result in severe
injury or death.
Vibration hazard:
Apply just enough pressure to do the work. Applying
excess pressure to the tamper can cause operator
discomfort or temporary numbness.
• Inspect the hydraulic hoses and couplings every
operating day. Repair or replace if leakage, crack-
ing, wear, or damage is evident. Damaged hoses
or couplings can fail, resulting in injury or property
damage.
• Use this tool for manufacturer’s intended use only.
Use other than that which is described in this
manual could result in injury or property damage.
• Make sure all bystanders are clear of the work
area when handling, starting, and operating the
tool. Nearby personnel can be injured by ying
parts in the event of a tool malfunction.
Hydraulic oil can cause skin irritation.
• Handle the tool and hoses with care to prevent
skin contact with hydraulic oil.
• In case of accidental skin contact with hydraulic
oil, wash the affected area immediately to remove
the oil.
Failure to observe these precautions may result
in injury.
Procedure for connecting or disconnecting hydraulic
hoses, ttings, or components:
1. Move the ow lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Follow the sequence under “Hose Connections”
to prevent pressure buildup. In case some
pressure has built up, loosen hoses, ttings, or
components slowly.
Note: Keep all decals clean and legible, and replace
when necessary.
IMPORTANT SAFETY INFORMATION

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Pole Tampers
1. Serial Number Tag
2. Valve Body
3. Tube
4. ON/OFF Valve
5. Control Spool
6. Handle
7. Hydraulic Tank Port “T” (Return)
8. Hydraulic Pressure Port “P” (Supply)
9. Foot
12
3
4
5
9
8 7
12
6
3
5 7 8
9
12
78
3
9
H4802 • H4802-1 H4802-3 • H4802-5 H4802-6

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Specifications
Pole Tampers
Type of Hydraulic System.............................Open-center
or closed-center
Pressure Port........................ 9/16–18 female SAE O-ring
Return Port ............................. 3/4–16 female SAE O-ring
Blows per Minute
@ 15 l/min (4 gpm) ................................................. 980
@ 19 l/min (5 gpm) ............................................... 1160
@ 23 l/min (6 gpm) ............................................... 1300
Noise Levels
LWA (sound power level)....................................10 bels
LpCpeak (peak emission sound pressure)...........103 dB
Vibration ..........................................................53.75 m/s2
Length
H4802....................................................1524 mm (60")
H4802-1 ................................................2134 mm (84")
H4802-3 ................................................1830 mm (72")
H4802-5 ................................................1520 mm (60")
H4802-6 ................................................1524 mm (60")
Width .............................................................102 mm (4")
Mass/Weight
H4802.................................................... 10.4 kg (23 lb)
H4802-1 ................................................ 12.7 kg (28 lb)
H4802-3 ................................................ 10.4 kg (23 lb)
H4802-5 ................................................... 10 kg (22 lb)
H4802-6 ................................................ 10.4 kg (23 lb)
Tamper Foot (kidney-shaped)............... 64 mm x 203 mm
(2.5" x 8")
Hydraulic Power Source
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 23 l/min (6 gpm)
• Pressure relief: 138 bar (2000 psi)
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Type of Hydraulic System.............................Open-center
or closed-center
Flow
Minimum ............................................ 15 l/min (4 gpm)
Recommended................................... 19 l/min (5 gpm)
Maximum ........................................... 23 l/min (6 gpm)
Filtration.............................................10 micron (nominal)
Pressure Relief Setting ........................ 138 bar (2000 psi)
Back Pressure (maximum*) .................. 13.8 bar (200 psi)
* 13.8 bar (200 psi) is the maximum agreed standard back pressure
for the HTMA (Hydraulic Tool Manufacturers Association).
Greenlee Utility tools will operate satisfactorily at this standard.
1. Maximum hydraulic uid temperature must not
exceed 60 °C (140 °F). A sufcient oil cooling
capacity is needed to limit the hydraulic uid
temperature.
2. Hydraulic ow must not exceed 23 l/min (6 gpm).
Install a ow meter in the return line to measure the
rate of hydraulic ow before using the tool.
3. Pressure relief valve setting must not exceed
138 bar (2000 psi) at your tool’s maximum ow.
Locate the pressure relief valve in the supply circuit
to limit excessive hydraulic pressure to the tool.
Hydraulic Schematic
FILTER
(10 MICRON)
COOLER
RELIEF
VALVE
138 bar
(2000 psi)
CONTROL
VALVE FLOW METER
T
PTOOL
RESERVOIR
PUMP
POWER SOURCE
Recommended Hydraulic Fluids
Use any nondetergent, petroleum-based hydraulic
uid which meets the following specications or HTMA
specications.
S.U.S. @
38 °C (100 °F).............................................. 140 to 225
99 °C (210 °F)........................................... 40 minimum
Flash Point................................ 170 °C (340 °F) minimum
Pour Point................................. –34 °C (–30 °F) minimum

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Hoses and Fittings
Installation and Maintenance
Refer to publication 99930323, SAE J1273
(Hose and Hose Assemblies).
Replacement
Refer to a Greenlee Utility catalog or publication
99910322, Low Pressure Quick Couplers, Adapters and
Hoses.
Do not disconnect tool, hoses, or ttings while
the tool is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Setting the Super Spool™
H4802-3 and H4802-5 Only
The Super Spool allows the tool to be used with either
open-center or closed-center hydraulic systems.
1. Insert a screwdriver into the spool recess.
2. If using:
• Open-center hydraulic system, turn the
Super Spool counterclockwise until it stops.
• Closed-center hydraulic system, turn the
Super Spool clockwise until it stops.
OC CC

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Hose Connections
Tool Port Identification
Three methods are used to identify the pressure and
return ports of Greenlee Utility tools. Match the mark-
ings on your tool to this table.
Pressure Port Return Port
P T
or
In Out
or
9/16–18 O-ring Boss
(smaller port) 3/4–16 O-ring Boss (larger port)
H4802-3 and H4802-5:
Connecting Hoses
1. Move the ow lever on the power source to the
OFF position.
2. Stop the hydraulic power source.
3. Connect the return hose to the return port on the
power source, then to the return port on the tool.
4. Connect the pressure hose to the pressure port
on the tool, then to the pressure port on the power
source.
Pressure
(Port P)
Return
(Port T)
Disconnecting Hoses
1. Move the ow lever on the power source to the
OFF position.
2. Stop the hydraulic power source.
3. Disconnect the pressure hose from the power
source, then from the tool.
4. Disconnect the return hose from the tool, then from
the power source.
5. Install dust caps over the ports to prevent
contamination.
Typical Setup

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Hose Connections (cont’d)
H4802, H4802-1, and H4802-6:
Connecting Hoses
The remote valve can be used
on both open-center and closed-
center systems by adjusting the
OC/CC selection spool.
• For open-center pump opera-
tion, use a at head screwdriver
to turn the spool counterclock-
wise until it backs into the snap
ring.
• For closed-center operation, tighten the spool in the
clockwise direction until snug.
When connecting or disconnecting the remote
valve, always ensure that the valve is in the off posi-
tion and the system is depressurized.
Failure to observe this warning could result in severe
injury or death.
Connecting Remote Valve
When connecting the remote valve to the system,
connect lines in order as numbered in the diagram
below (1–2–3–4).
Disconnecting Remote Valve
When disconnecting the remote valve, remove lines in
reverse order of the numbering in the diagram below
(4–3–2–1).
Selection
Spool
OC CC
Typical Setup
3
4
1
2
Return Return
Pressure Pressure

H4802 Series Pole Tampers
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Setup
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 23 l/min (6 gpm)
• Pressure relief: 138 bar (2000 psi)
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Do not reverse hydraulic ow. Operation with
hydraulic ow reversed can cause tool malfunction.
Connect the supply (pressure) hose and return (tank)
hose to the proper tool ports.
Failure to observe this warning could result in severe
injury or death.
1. Stop the power source.
H4802-3 and H4802-5 only: Set the control spool
as described under “Setting the Super Spool.”
2. Connect the hoses as described under “Hose
Connections.”
Operation
Electric shock hazard:
This tool is not insulated. When
using this unit near energized elec-
trical lines:
• Use only certied non-conductive
hoses and proper personal protec-
tive equipment.
• Select and maintain the hydraulic
uid to meet the minimum dielec-
tric standards required by your
safety department.
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punctures
skin causing serious injury, gangrene
or death. If you are injured by
escaping oil, seek medical attention
immediately.
Do not disconnect tool, hoses, or ttings while
the tool is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Maintain a rm grip on tool, using both hands at all
times. Serious injury can result if an operator does
not control the tool.
Failure to observe this warning could result in severe
injury or death.